Lopi AGP Pellet Insert Owner's manual

AGP

(All Grade Pellet)

Troubleshooting Guide

Travis Industries Certied Factory Training Program

Document 176-01795

Press the START button on the control panel. The stove will enter the start-up sequence for

approximately 22 min.

• 1. Green light will start to ash in start up mode.

• 2. Exhaust blower will come on.

• 3. Push Auger will turn.

Green

light will

start to ash in

START-UP

mode

SEE NEXT PAGE.

NO

GREEN

LIGHT

To START Manually

YES

The unit has been programmed to evacuate smoke in case of a power failure. When 110V is

introduced to the unit the exhaust fan will start and operate approximately 15 minutes, and the

RED stop light will illuminate.

NO

Exhaust

Blower

Comes

On?

IF CONTROL BOARD IS FLASHING EITHER A RED LIGHT OR BLUE LIGHT, OR HAS

CONSTANT RED AND GREEN, REFER TO DIAGNOSTIC CHART.

Plug

stove into

outlet. Does

convection fan

come

on?

• 4. Meter System will turn.

• 5. Pellets will start to feed the system.

• 6. Igniter will come on.

NO

YES

1. Check system disc for continuity.

1. If no power, check fuses on control board and the

inline fuse on the back of the unit. (See Diagram 4).

2. If there is power to the board and GREEN light

does not come on when the start button is depressed.

Replace the control board.

1. Check continuity of exhaust blower or connect power

directly to the blower. If blower does not function and

there are no obstructions in the blower housing,

replace blower.

2. Check wiring connection. (See Diagram 1). Check

pathway for continuity from pin #4 to the end of the

Black wire and pin #7 to White wire.

3. Is the blower getting power? If not receiving power

check fuses on control board and power supply. If

fuses are good you will see the ashing GREEN light,

if not replace board. (See Diagram 4).

1

AGP™ Pellet Troubleshooting

NO

1. Push auger must be operational for meter motor to operate.

2. Is the Start light ashing?

3. Are there pellets in the hopper?

4. If push auger is turning and Stop light on control board is

ashing, Check encoder for proper voltage to and from control

board and if Molex is connected to the control board.

(See Diagram 3). Check continuity of metering motor.

5. Check for power to the meter motor, this will be an intermittent

power supply. (See Diagram 2).

6. Is hopper lid closed and lid switch actuated?

7. Connect power direct to motor to determine if operational.

(If slight movements check for jam)

8. Check Hopper lid switch for continuity.

9. Check Horizontal Rotating Disc (HRD) assembly for

fouling or jam.

10. Check pathway (with hopper CLOSED) from pin #6 to the end

of the RED wire pin #7 to WHITE wire.

11. Check to see if encoder molex is plugged in at board.

12. Remove pellets from the hopper; disconnect metering

motor to determine if HRD is spinning freely.

NOTE: Do not use a wrench or socket drive on 7/16”

retaining bolt on HRD to free a jam. Serious

damage can occur or bolt can be broken.

If this happens the stove must be returned

for repair.

Meter Motor

Turning

(HRD)?

YES

SEE NEXT PAGE.

Push

Auger

Turning?

YES

NO

1. Check vacuum and brass barb tube for blockage,

kinks, or cracks.

2. Check ow switch for continuity. No continuity

through ow switch when actuated, replace ow switch.

3. Check continuity of motor.

4. Check jumper wire between ow switch and push

auger for continuity. Check continuity from pin #7 to

White wire. If no continuity replace wiring.

5. Check for power to motor, this should be a constant

power supply (See Diagram 2).

6. Connect power direct to motor to determine if

operational. If not turning replace motor.

7. Check auger ight for jam.

8. If the ow switch is good and still no power to motor,

replace control board.

2

AGP™ Pellet Troubleshooting

NO

AGP™ Pellet Troubleshooting

Igniter

Comes On

1. Check to see if the wires are connected?

2. Check igniter for continuity. Ohms should be

(57Ω +10/-5) (If ohms not in range replace igniter).

(See Diagram 2).

3. Check for voltage to the Igniter? No voltage,

check fuse. Check that unit is in start mode with

ashing green light. Not working? Replace control

board.

4. Check pathway continuity from pin #1 to the end of

the BLACK wire and pin #7 to the WHITE wire.

NOTE: Igniter is accessed through combustion

chamber and behind burn platform.

(See Diagram 5).

3

Pellets

Ignite

YES

NO

1. Pellets should ignite between 5-15 minutes from the

time the start button is pushed.

2. Check the gaskets on the door, the ash door and

that both are latched.

3. Ensure exhaust access panel behind ash pan is

in place.

NO

1. If the green light does not stay on and the red

light comes on, this indicates the unit has gone

into shut down.

2. Check the systems disc for continuity when

heated. If no continuity, replace systems disc.

1. Check Systems disc for continuity.

If no continuity when hot replace System disc.

2. Jumper Systems disc and check power supply to

convection blower.

If no power when systems disc is jumped, replace

control board.

3. Check continuity or connect power direct to

blower. If there is no continuity or blower does

not function with direct power, replace blower.

4

AGP™ Pellet Troubleshooting

Green

Light Goes

to Constant

Glow?

YES

RUN MODE

NO

Convection

Blower

Comes

On

SHUT DOWN MODE

Press the STOP button on the control panel. The stove will begin the shut-down process,

which takes approximately 45 minutes.

1. The metering auger will stop feeding pellets, but the push auger stays running.

2. When the unit gets cool the convection blower will shut off while the combustion

2. blower stays running for another 15 minutes.

3. The unit is now off and waiting to be started.

5

AGP™ Pellet Troubleshooting

THERMOSTAT MODE

Tstat calls for heat.

1. Unit will go into start mode. Unit will start same as manually.

See manual start.

The stove will enter the start-up sequence for approximately 22 min.

See manual start.

Changing the TSTAT Program

This heater comes with three TSTAT programs built in. Each program is unique and allows

you to modify your thermostat setting to your preference. The stove is shipped pre-pro-

grammed in TSTAT program 1.

How to Tell Which TSTAT Program You Are In

When you press the “STOP” and “TSTAT” button simultaneously while the unit is cold the

blue Auto-Fan LED light will ash. It will ash once for Program 1, twice for Program 2, and

three times for Program 3. Flashes are quick.

Switching Between Program 1, 2, and 3

Each time you press the “STOP” and “TSTAT” button simultaneously while the unit is cold,

the TSTAT program will toggle to the next program. Continue to press these two buttons until

the blue Auto-Fan LED light ashes the program you wish to use.

Thermostat Program 1

When the thermostat stops calling for heat (the thermostat is open) the feed rate “steps down” to

a lower heat setting. The heater will stay at this setting for 15 minutes. If the thermostat does not

call for heat, the feed rate will “step down” again to a lower setting (or off).

At any time if the thermostat calls for heat (thermostat is closed) during this cycle, the heater

will resume at the HEAT output setting set at the control board.

If it switches to off and there is a call for heat it will switch to start up mode for the 22 min.

cycle before returning to its board setting.

THERMOSTAT PROGRAM 2

In Thermostat Mode Program 2 when the thermostat stops calling for heat (the thermostat is

open) the following happens:

The burn rate decreases to Level 1 (low) for 15 minutes. If there is no call for heat during

that time…

The unit turns off. If there is a call for heat by the thermostat (the thermostat is closed) at

any point during this cool-down period then the burn rate resumes corresponding with the

setting on the control panel.

THERMOSTAT PROGRAM 3

In Thermostat Mode Program 3 when the thermostat stops calling for heat (the thermostat is

open) the following happens:

The burn rate decreases to Level 1 (low) and remains at this level until there is a call for

heat by the thermostat (the thermostat is closed), then resumes corresponding with the set-

ting on the control panel.

Run mode. Same as manual mode.

Shut Down. Same as manual mode.

6

AGP™ Pellet Troubleshooting

THERMOSTAT MODE

7

AGP™ Pellet Troubleshooting

8

AGP™ Pellet Troubleshooting

Flow Switch

System Snap Disc

Exhaust/Combustion

Blower

Stove - Diagram 1

9

AGP™ Pellet Troubleshooting

Meter Motor

(HRD)

Push Motor

with Encoder

Convection Blower

Encoder

Molex

Igniter

Wires

Safety Snap

Disc

Grey Wires

go to

Hopper Snap

Disc

Stove - Diagram 2

10

AGP™ Pellet Troubleshooting

Meter Motor

(HRD)

Push Motor

with Encoder

Igniter

Wires

INSERT - Diagram 1

Cooling Fan

Cooling

Fan Fuse

Flow Switch

Convection

Fan

Push Auger

Exhaust

Blower

Encoder

Molex

11

AGP™ Pellet Troubleshooting

Insert - Diagram 2

Control

Panel

Light

Molex

Encoder

Molex

Hopper Lid

Switch

Connection

Inline

Fuse

Control

Panel

Light

Micro

Switch

Cooling Fan Cooling

Fan Fuse

0.5 AMP/125 v

12

AGP™ Pellet Troubleshooting

5

Set To

DCV

Set To

DCV

Voltage DC

Take measurements from the Molex Connector (either side)

If no power check molex connection at control board. If good replace control board.

2.5

5 VDC

2.5 VDC

To Red and

Black Wires

To White and

Black Wires

If not 2.5 VDC and you are reading 5 VDC through

the RED and BLACK wires, replace the Pusher Auger.

Diagram 3 - Encoder Voltage Test

Voltage DC

13

AGP™ Pellet Troubleshooting

5amp/125v Fuse

Encoder Molex

Diagram 4

STOVE

5amp/250v Fuse

Back Of Unit

INSERT

5amp/250v Fuse

Bottom of

Control Board

14

AGP™ Pellet Troubleshooting

Burn Platform

Igniter

Diagram 5 - Ignitor

15

AGP™ Pellet Troubleshooting

16

AGP™ Pellet Troubleshooting

AGP™ Pellet Insert

Lopi AGP Pellet Insert, AGP Pellet Stove Owner's manual

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